U.S. patent application number 09/784860 was filed with the patent office on 2002-08-22 for removable mounting bracket for expanded plastic foam articles.
Invention is credited to Musal, Michael J..
Application Number | 20020112277 09/784860 |
Document ID | / |
Family ID | 25133748 |
Filed Date | 2002-08-22 |
United States Patent
Application |
20020112277 |
Kind Code |
A1 |
Musal, Michael J. |
August 22, 2002 |
REMOVABLE MOUNTING BRACKET FOR EXPANDED PLASTIC FOAM ARTICLES
Abstract
The mounting bracket of the present invention includes an
integrally molded head portion and article attachment portion that
are formed of a flexible plastic material. The head portion is
shaped for insertion into a cavity that is molded into an EPS
article of manufacture such as a bicycle helmet. The flexible
plastic head portion expands upon insertion into the cavity, such
that it engages sidewall portions of the cavity and resists pulling
forces that tend to remove it from the cavity. In the preferred
embodiment, the head portion is generally shaped like a ladder,
having two side rails and a plurality of rung members disposed
therebetween. The cavity formed within the EPS foam is shaped to
receive the head portion in a collapsed configuration. After the
collapsed head portion is inserted within the cavity, it expands
such that the outer surfaces of the side rails are pressed against
sidewall surfaces of the cavity. A pulling force on one of the side
rails tends to force the two side rails apart, increasing the
lateral force of the side rails against the cavity walls, thus
enhancing the engagement of the head within the cavity. An
outwardly depending pull tab may be integrally formed with the
other side rail to facilitate the release of the head from the
cavity. A bicycle helmet of the present invention includes the
shaped cavity together with the mounting bracket that is formed for
mating insertion within the cavity.
Inventors: |
Musal, Michael J.; (Soquel,
CA) |
Correspondence
Address: |
INTELLECTUAL PROPERTY LAW OFFICE
1901 S. BASCOM AVENUE, SUITE 660
CAMPBELL
CA
95008
US
|
Family ID: |
25133748 |
Appl. No.: |
09/784860 |
Filed: |
February 15, 2001 |
Current U.S.
Class: |
2/418 |
Current CPC
Class: |
A42B 3/14 20130101; A42C
2/00 20130101; Y10S 411/913 20130101; A42B 3/147 20130101; F16B
21/084 20130101 |
Class at
Publication: |
2/418 |
International
Class: |
A42B 001/22 |
Claims
What is claimed is:
1. A mounting bracket for engaging objects to expanded plastic foam
(EPS) articles of manufacture, comprising: an integrally molded
head portion and object attachment portion, said head portion
including: a first side rail; a second side rail; a plurality of
rung members being disposed between said first side rail and said
second side rail; said rung members including a generally thick
central portion and generally thin end portions, each said end
portion being integrally molded with one of said side rails.
2. A mounting bracket as described in claim 1 wherein said mounting
bracket is comprised of a flexible plastic material.
3. A mounting bracket as described in claim 1 wherein said first
and second side rails include outer side edges having serrated
surfaces.
4. A mounting bracket as described in claim 3 wherein said outer
edge of said first side rail member and said second side rail
member converge at an angle of approximately 6.degree..
5. A mounting bracket as described in claim 1 wherein said first
rail member and said second rail member include inner side edges
that are generally parallel to each other.
6. A mounting bracket as described in claim 1 wherein said
attachment portion includes an upper enlarged heel portion and a
lower article attachment end.
7. A mounting bracket as described in claim 1 wherein said first
side rail member includes a base portion and a tip portion, and
wherein said base portion is wider than said tip portion.
8. A mounting bracket as described in claim 1 wherein a mounting
release member is integrally formed with said second side rail.
9. A bicycle helmet comprising: an expanded plastic foam portion
having at least one article attachment cavity formed therein, said
attachment cavity including two opposed sidewalls and two opposed
endwalls; a strap member having at least one mounting bracket
engaged therewith, said mounting bracket being formed for mating
engagement within said cavity; said mounting bracket including: an
integrally molded head portion and object attachment portion, said
head portion including: a first side rail; a second side rail; a
plurality of rung members being disposed between said first side
rail and said second side rail; said rung members including a
generally thick central portion and generally thin end portions,
each said end portion being integrally molded with one of said side
rails.
10. A bicycle helmet as described in claim 9 wherein said mounting
bracket is comprised of a flexible plastic material.
11. A bicycle helmet as described in claim 9 wherein said first and
second side rail members include outer side edges having serrated
surfaces for enhanced frictional engagement with said opposed
endwalls of said cavity.
12. A bicycle helmet as described in claim 11 wherein said outer
edges of said first side rail member and said second side rail
member converge at an angle of approximately 6.degree..
13. A bicycle helmet as described in claim 12 wherein said cavity
endwalls converge at an angle of approximately 6.degree..
14. A bicycle helmet as described in claim 9 wherein said first
rail member and said second rail member include inner side edges
that are generally parallel to each other.
15. A bicycle helmet as described in claim 9 wherein said
attachment portion includes an upper enlarged heel portion and a
lower article attachment end.
16. A bicycle helmet as described in claim 9 wherein said first
side rail member includes a base portion and a tip portion, and
wherein said base portion is wider than said tip portion.
17. A method for mounting objects to an expanded plastic foam
article of manufacture comprising the steps of: forming an expanded
plastic foam article of manufacture such that an article engagement
cavity is formed therein, said article engagement cavity including
two opposed sidewalls and two opposed endwalls; forming an
integrally molded article mounting bracket, said mounting bracket
including: an integrally molded head portion and object attachment
portion, said head portion including: a first side rail having an
outer side edge thereof; a second side rail having an outer side
edge thereof; a plurality of rung members being disposed between
said first side rail and said second side rail; said rung members
including a generally thick central portion and generally thin end
portions, each said end portion being integrally molded with one of
said side rails. inserting said mounting bracket into said cavity
such that said outer side edges of said side rails make contact
with said opposed endwalls of said cavity; said mounting bracket
having a central axis thereof and said rail members having a
longitudinal axis thereof and wherein an angle between said central
axis and said longitudinal axis is between 35.degree. and
55.degree. when said mounting bracket is inserted within said
cavity.
18. A method as described in claim 17 wherein said angle is
approximately 45.degree..
19. A method as described in claim 17 wherein said cavity endwalls
are formed with a draft angle of approximately 3.degree., and said
outer edges of said side rails converge with an included angle of
approximately 6.degree..
20. A method as described in claim 17 wherein said mounting bracket
is comprised of a flexible plastic material.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates generally to mounting devices
for the attachment of objects to expanded plastic foam articles of
manufacture, and more particularly to a removable mounting bracket
for engaging helmet fitting straps to expanded polystyrene (EPS)
bicycle helmets.
[0003] 2. Description of the Prior Art
[0004] The attachment of various articles, such as straps, to
expanded plastic foam articles of manufacture, such as expanded
polystyrene (EPS) bicycle helmets, has been accomplished in several
ways. Openings can be molded into the EPS article such that straps
or other objects can be looped through the openings and affixed
thereto. Other types of engagement methods have included the
placement of an anchor piece within an EPS mold for an article
followed by the injection of EPS foam into the mold and the
subsequent removal of the article from the mold, such that the
anchor piece is molded in the hardened EPS article. Still other
types of engagement methods have included the use of Velcro where
one portion of the mating Velcro pieces is glued to the EPS
article.
[0005] Each of these prior art methods has its drawbacks. Looped
straps can be too loose fitting; molded in anchors can become
difficult to orient in a repeatable manner during manufacture and
adhesively bonded attachment devices such as Velcro can become
detached where the adhesive fails.
[0006] The present invention solves these problems by providing a
releasable anchor that is inserted within a cavity that is molded
into the EPS article. As will be understood from the following
disclosure, the anchor is easily inserted into the cavity and
expands following insertion to resist pulling forces that act to
remove it. It therefore provides a simple, strong yet releasable
anchor for various articles such as a head fit strap for a bicycle
helmet.
SUMMARY OF THE INVENTION
[0007] The mounting bracket of the present invention includes an
integrally molded head portion and article attachment portion that
are formed of a flexible plastic material. The head portion is
shaped for insertion into a cavity that is molded into an EPS
article of manufacture such as a bicycle helmet. The flexible
plastic head portion expands upon insertion into the cavity, such
that it engages sidewall portions of the cavity and resists pulling
forces that tend to remove it from the cavity.
[0008] In the preferred embodiment, the head portion is generally
shaped like a ladder, having two side rails and a plurality of rung
members disposed therebetween. The cavity formed within the EPS
foam is shaped to receive the head portion in a collapsed
configuration. After the collapsed head portion is inserted within
the cavity, it expands such that the outer surfaces of the side
rails are pressed against sidewall surfaces of the cavity. A
pulling force on one of the side rails tends to force the two side
rails apart, increasing the lateral force of the side rails against
the cavity walls, thus enhancing the engagement of the head within
the cavity. An outwardly depending pull tab may be integrally
formed with the other side rail to facilitate the release of the
head from the cavity.
[0009] A bicycle helmet of the present invention includes the
shaped cavity together with the mounting bracket that is formed for
mating insertion within the cavity.
[0010] It is an advantage of the present invention that a mounting
bracket is provided for the releasable attachment of an object with
an EPS article of manufacture.
[0011] It is another advantage of the present invention that a
mounting bracket is provided for the attachment of an object to an
EPS article of manufacture wherein the mounting bracket is an
integrally molded device.
[0012] It is a further advantage of the present invention that a
mounting bracket is provided in which an increased pulling force
generates an increased resistive force against the removal of the
mounting bracket.
[0013] It is yet another advantage of the present invention that a
reliable mounting bracket is provided that comprises a single
integrally molded piece.
[0014] These and other features and advantages of the present
invention will no doubt become apparent to those skilled in the art
upon reading the following detailed description which makes
reference to the several figures of the drawings.
IN THE DRAWINGS
[0015] FIG. 1 is a plan view of a bicycle helmet fit strap of the
present invention including four EPS anchors of the present
invention;
[0016] FIG. 2 is a front elevational view of an anchor of the
present invention;
[0017] FIG. 3 is a side elevational view of the anchor depicted in
FIG. 2;
[0018] FIG. 4 is a perspective view depicting an anchor cavity of
the present invention formed within an EPS article of manufacture
such as a bicycle helmet;
[0019] FIG. 5 is a front elevational view depicting a collapsed
configuration of the anchor of FIG. 2 inserted within the cavity of
FIG. 4; and
[0020] FIG. 6 is a front elevational view depicting the anchor
engaged within the cavity of FIG. 4.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] The anchor device of the present invention is designed to
provide a secure yet releasable engagement of an object with an
expanded plastic foam article of manufacture. A particular
application of the present invention is the utilization of the
anchor to attach a fit-strap to the inner portions of an expanded
polystyrene (EPS) bicycle helmet, and FIG. 1 is a plan view of such
a bicycle helmet fit-strap 14 which includes four anchors 10 of the
present invention. As depicted in FIG. 1, the fit-strap 14 is
comprised of a particularly shaped band of material, such as cloth
or plastic, having a head engagement band portion 18 for engagement
with a wearer's head, and helmet engagement band portions 22 to
which the attachment anchors 10 of the present invention are
engaged, and which serve to attach the fit-strap 14 to interior
portions of an EPS helmet (not shown). Matingly engagable end
portions 26 of the strap 14 are provided for engagement together,
such that the fit-strap 14 forms a band around the wearer's head.
Fit-straps are generally well known in the art, and the fit-strap
of the present invention is unique in that it includes the anchors
10 of the present invention for releasable engagement with a
bicycle helmet, as is described herebelow.
[0022] FIG. 2 is a front elevational view of a preferred embodiment
of an anchor 10 of the present invention, and FIG. 3 is a side
elevational view of the anchor 10 depicted in FIG. 2. As depicted
in FIGS. 2 and 3, the anchor 10 generally includes an anchor head
portion 40 and an article attachment end portion 44. The anchor
head 40 is preferably integrally formed with the attachment end 44,
such that the anchor 10 is preferably formed as a single integrally
molded piece and is composed of a flexible plastic material. The
article attachment end portion 44 is depicted as a thin elongated
end portion that projects from the head portion 40 and may be
integrally molded with the engagement bands 22 of the fit strap 14;
however, the attachment end 44 may take many forms and shapes as
are generally required for the attachment of the anchor 10 to an
object, such as the fit-strap depicted in FIG. 1. In the attachment
strap depicted in FIGS. 1 and 2, a thin flexible section 46 may be
formed proximate the head 40 to provide further flexibility to the
attachment strap 44 and facilitate the insertion of the head 40
into an anchor cavity 120 as is depicted in FIG. 4 and described in
detail herebelow. However, where the anchor 10 is utilized to
attach objects other than the fit-strap 14 of FIG. 1, the
attachment end 44 may be formed in various shapes and sizes as are
required to engage such objects.
[0023] The head 40 may be generally thought of as having a ladder
shaped structure including a first side rail 50, a second side rail
58 and a plurality of rungs 66 integrally formed between the side
rails 50 and 58. Each of the rungs 66 is formed with a wide,
central body portion 74 and narrow end portions 82 formed at the
juncture of the rung body portion 74 with the side rails 50 and 58.
The outer edges of the side rails 50 and 58 are preferably formed
with a series of downwardly projecting serrations or teeth 92 which
serve to aid in the engagement of the anchor 10 within a foam
plastic article of manufacture such as an EPS bicycle helmet, as is
described more fully herebelow. The first side rail 50 is
preferably formed with a relatively wide base portion 100 that
supports the engagement of the anchor head 40 with the attachment
end 44 to provide a strong, reliable engagement of the head portion
40 with the attachment end 44, where pulling forces are applied to
the attachment end 44 during usage of the anchor 10. The upper
portion 104 of the attachment end 44 may be formed with an enlarged
heel portion 108 that includes a flat angled surface 112. The
functional purpose of the heel portion 108 is described hereinbelow
with the aid of FIG. 5.
[0024] As indicated hereabove, the anchor 10 is designed for
releasable engagement with an expanded plastic foam article of
manufacture such as an EPS bicycle helmet, and without limiting the
general application of the present invention, the following
discussion refers to a bicycle helmet as the article of
manufacture. To accomplish the releasable engagement of the anchor
10 to the EPS bicycle helmet, a shaped cavity 120, as depicted in
FIG. 4, is formed in the EPS helmet 121 at the desired attachment
location of the anchor 10. The cavity 120 is formed with two
sidewalls 122 and two endwalls 124, such that the cavity 120 has a
generally rectangular cross-section. The sidewalls 122 have a
length 128 that generally corresponds to the width 134 of the
anchor head 40 depicted in FIG. 2, the endwalls 124 have a width
140 that generally corresponds to the thickness 144 of the anchor
head 40 as depicted in FIG. 3, and the cavity 120 has a depth 152
that generally corresponds to the height 156 of the anchor head
140, such that the anchor head 40 is insertable within the cavity
120. To accomplish the releasable engagement of the anchor 10
within the cavity 120 the dimensions and tolerances of the anchor
head 10 and the cavity 120 require further discussions, as is next
provided with the aid of FIGS. 5 and 6.
[0025] FIG. 5 is a front elevational view of the anchor 10 depicted
in a collapsed configuration and inserted within the cavity 120,
and FIG. 6 is an elevational view of the anchor engaged within the
cavity 120. The collapsed configuration of the anchor head 40 as
depicted in FIG. 5 is best understood by comparison with the head
configuration depicted in FIG. 2. Specifically, owing to the
flexible plastic material from which the anchor 10 is molded and
the relatively thin rung end portions 82, the second side rail 58
may be rotated downwardly (see arrow 180) relative to the first
side rail 50. The downward rotation 180 may be accomplished until
the lower edge 188 of the thickened rung portion 74 of the lowest
rung 196 makes contact with the upper surface 112 of the heel
portion 108 of the anchor 10. Owing to the generally
parallelogram-like configuration of the ladder-like head design,
each of the thicker central portions 74 of the rungs 66 are
likewise collapsed into contact against each other when the head 40
is in its fully collapsed configuration as depicted in FIG. 5. It
can be seen in FIG. 5 that the length 128 of the cavity 120 is
greater than the width of the collapsed head depicted in FIG. 5,
such that the teeth 92 of the side rails 50 and 58 do not
simultaneously contact both endwalls 124 of the cavity 120.
[0026] FIG. 6 depicts the anchor head 40 in engagement within the
cavity 120. As depicted therein, the second side rail 58 has
rotated upwardly (see arrow 210) such that the teeth 92 of side
rail 50 as well as teeth 92 of side rail 58 simultaneously make
contact with the endwalls 124 of the cavity 120. In the preferred
embodiment, the resilient nature of the flexible plastic of the
anchor 10 naturally results in the upward rotation 210 of the
second side rail 58, where the anchor 10 is molded in the open
configuration depicted in FIG. 2. As will now be obvious to those
skilled in the art, when a downward force 218 is applied to the
attachment end 44 of the anchor 10, the anchor head will become
even more tightly engaged within the cavity 120. This is because a
downward motion of the attachment end 44 will cause a corresponding
downward motion of the first side rail 50 owing to the integrally
formed nature of the head. However, any downward motion of the
first side rail 50 will create a lateral, outward force between the
first side rail 50 and the second side rail 58 owing to the angular
orientation of the rungs 66 between the side rails and the
engagement of the teeth 92 of side rail 58 with the endwall 124 of
the cavity. More specifically, the head 40 has a vertical central
axis 230 and each rung 66 can be thought of as having a
longitudinal central axis 238 that exists between the two narrow
ends 82 of each rung 66, such that an angle b is formed between the
central head axis 230 and the rung axis 238 of each rung 66. It
will therefore be appreciated by those skilled in the art that
general downward movement of the first side rail 50 relative to the
second side rail 58 will cause angle b to increase and create a
corresponding lateral outward movement of side rails 58 and 50
relative to each other until angle b could be approximately as much
as 90.degree.. Therefore, the dimensions of the cavity 120 and the
anchor head 40 can conceivably be selected such that the engagement
of the two side rails 50 and 58 with the endwalls 124 of the cavity
120 may occur anywhere from an angle b of about 90.degree. down to
a relatively steep angle b such as 25.degree. (where the head is in
a fully collapsed configuration). Significantly, however, as will
be understood by those skilled in the art, a relatively weak head
engagement within the cavity will occur where angle b is at its
extreme of approaching 90.degree. and at its minimum of approaching
25.degree., whereas a relatively strong engagement of the anchor
head within the cavity 120 will occur where angle b is in a
generally mid-range of approximately 35.degree. to approximately
55.degree. with a preferred angle of approximately 45.degree..
Where angle b is less than approximately 35.degree., the anchor
head 40 tends to pull out of the cavity 120 too easily and without
significant opening of angle b, and where angle b is greater than
approximately 60.degree., the anchor head 40 may be pulled out of
the cavity 120 too easily because the lateral force generated
between the two side rails 50 and 58 against the endwalls 124 of
the cavity 120 does not increase sufficiently as the side rails 50
and 58 separate. Of course, these angles and angle ranges apply to
the head embodiment depicted in FIGS. 1-3, 5 and 6, and may not
apply to other head rail/rung configurations that may be developed
by those skilled in the art.
[0027] A significant feature of the present invention is that the
side rails 50 and 58 apply a uniform outward force throughout the
depth of the cavity endwalls 124. That is, as is best seen in FIG.
6, each of the rungs 66 is disposed at a substantially identical
angle relative to the central axis of the head 40, and each rung 66
therefore applies an equal outward force between the side rails 50
and 58 at each rung location when a downward force 218 is applied
to the attachment end 44. Thus, the general parallelogram nature of
the ladder configuration of the head 40 results in equal lateral
force being applied throughout the length of each side rail 50 and
58 against the interior endwalls 124 of the cavity 120, whereby a
superior engagement of the head 40 within the cavity 120 is
accomplished with the head configuration of the present
invention.
[0028] It is typical though not necessary in forming molded
cavities, such as cavity 120 that the sidewalls 122 and endwalls
124 are not exactly parallel, but rather are formed with a small
angular draft, such that a mold cavity creating insert can be
removed from the cavity 120 upon the opening of the mold, and such
a cavity wall draft is typically on the order of 1.degree. to
3.degree. from the central axis of the cavity. To accomplish the
generally uniform lateral force of the side rails 50 and 58 against
cavity endwalls 124 having a draft angle such as 1.degree. to
3.degree., the head 40 is preferably constructed such that the
serrated outer edges of the side rails 50 and 58 diverge from the
central axis 230 at a corresponding angle of 1.degree. to
3.degree.. Alternatively, the head can be constructed such that the
first side rail 50 is tapered from its top region 280 to its base
region 100 such that the right side rail's outer edge 292 diverges
from the right side rail's inner edge 296 at an angle which is
twice the draft angle, or approximately 2.degree. to 6.degree.
where the draft angle of the cavity is 1.degree. to 3.degree.. In
these configurations, the teethed outer edges of the side rails
will be parallel to the corresponding endwalls 124 of the cavity
120 as the head 40 expands (arrow 210) within the cavity 120.
Uniform contact of the teeth 92 of the side rails 50 and 58 with
the cavity endwalls 124 will occur when the head expansion occurs,
as has been discussed hereabove.
[0029] It is to be noted that the thickened central portions 74 of
the rungs 66 serves an important purpose of inhibiting a twisting
collapse of the rungs 66 where a significant downward force 218
acts to pull the head 40 from the cavity 120. That is, if the rungs
66 were as thin as end portions 82 throughout the length of each
rung 66, then a significant pulling force 218 could cause such thin
rungs to bend or twist throughout their length, such that the
lateral outward force of the side rails 50 and 58 against the
cavity endwalls 124 could suddenly decrease, with a result that the
head 40 would be pulled from the cavity 120. The thickened central
portions 74 of the rungs 66 act to prevent such bending and
twisting of the rungs, and thereby serve to provide strength to the
anchor head 40. Where it is desired to provide an easily removable
anchor, an anchor releasing pull tab 320 may be formed at the lower
end of side rail 58. Where the anchor head 40 is engaged within a
cavity 120, as depicted in FIG. 6, a downward force applied to the
pull tab 320 will cause the head 40 to rotate towards the collapsed
configuration depicted in FIG. 5. When the head 40 is in the more
collapsed configuration, the side rail 58 becomes released from the
cavity endwall 124, and the head 40 can thereupon be easily removed
from the cavity 120.
[0030] It will be understood by those skilled in the art that
certain alterations and modifications of the anchor head 40 may be
made without departing from the true spirit and scope of the
present invention. A particularly significant feature of the
present invention is the collapsible/expandable ladder-like
configuration of the side rails and rungs of the head. This
configuration provides a uniform outward force between the side
rails as the head expands within the cavity. This results in a
uniform engagement force of the anchor head side rails against the
cavity side walls and thereby provide a strong engagement of the
anchor head within the cavity. While a preferred rung shape, and
preferred side rail shapes have been depicted herein, the present
invention is not to be so limited. That is, other rung shapes and
side rail shapes that nevertheless include the generalized
ladder-like configuration of the head will become obvious to those
skilled in the art upon reading this disclosure, and are deemed to
be within the scope of the present invention and the claims that
follow.
* * * * *